Abstract In recent decades, friction stir welding has emerged as a significant transformative technique in advanced manufacturing. In this work, fabricating the friction stir welding of 5 mm thick similar titanium grade 4 plates with varying weight percentages of naturally derived biochar (0, 1, 2, and 3 wt%) to enhance the mechanical properties and wear behavior. According to the test analysis, the biochar-included FSW samples had better mechanical properties than the plain-welded titanium sample. The 2 wt% biochar-induced FSW sample gets the best tensile result of 395 MPa, impact strength of 32.02 J, and fatigue result of 183 MPa. Through field emission scanning electron microscopy analysis, biochar was well dispersed throughout the regions and contributing to the grain nucleation. The bookend surfaces of the tensile fractured specimen were examined by using scanning electron microscopy analysis. According to micro-hardness and wear resistance test analysis, a 3 wt% biochar sample plays a key role in enhancing the results and getting 107 HV and a specific wear rate of 0.052 mm³/Nm×10 − 3 and a co-efficient of friction of 0.25 µ. The worn surface analysis was accomplished by scanning electron microscope analysis, and the wear mechanisms were studied. The novel approach of the present research is to suggest the ideal biochar FSW titanium sample for aerospace components in critical wear applications. This technique is currently gaining popularity and is being used in a variety of applications, including aviation, shipbuilding, aircraft companies, defense sectors, and the automotive industry. These are implemented to mitigate the detrimental effects and the emergence of defects in the joining of similar alloys in comparison to fusion welding techniques because of their energy-efficient, versatile, and eco-friendly process.
Giridharan et al. (Mon,) studied this question.